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I believe that the RPM limit of 2400 was set for noise abatement, not any mechanical reason.

I installed the PFlo on my 2002. Found increases in climb similar to Rich. I have flown the plane at 17,000 ft and it still wants to climb. 5-8 knot increase in cruise speed. Diamond performed flight tests of the system before adopting it as standard equipment. The Powerflo folks can send you the PowerPoint deck showing the test results. I found that on climb my installation provided an increase exceeding that shown in this document.

Even my skeptical aerobatics instructor said. —“ I hate to admit it but there is a very noticeable increase in power.” Note the aerobatics is not performed in the Diamond.

I wasn’t sure what to look for when preflighting the powerflow. This is what you don’t want to see. My insert was never replaced until today with 1036 on the tach.

This is prior to removing the remains of the old insert.


This is a comparison showing the new insert next to the pile of remains of the old one.


It will be interesting to see if any this affects the power output or sound level.

I added PF last year. Improvement in ceiling, climb rate and cruise speed

I can cruise 8000, 2500 rpm, 50 degrees ROP at 152 TAS,9.7 GPH
I usually run 2400 rpm, 60 degrees LOP, 8.1 GPH, at 142TAS

Ceiling is now over 17000. Still climbs at 200 fpm at 17000

Climb rate at around 1-2,000 msl, 90 knots is over 1100 fpm.

The Powerflow is a great investment. I never worry about any min climb rate IFR

Waouh impressive values! Makes me dream.
Unfortunately it is not possible to install PF on the DA40 anymore.

Just put it in last fall along with a new prop.. Yes you see some improvement but not enough to justify the cost, if you have to change your prop.

astaib wrote: ↑Sat Jun 06, 2020 6:37 am Waouh impressive values! Makes me dream.
Unfortunately it is not possible to install PF on the DA40 anymore.

??? Stephen just ordered one.

YCCA wrote: ↑Sat Jun 06, 2020 11:23 am Just put it in last fall along with a new prop.. Yes you see some improvement but not enough to justify the cost, if you have to change your prop.

Having to change the prop does (at least) double the cost. And for whatever reason, the cost of props has jumped the last couple of years.

Rich wrote: ↑Sat Jun 06, 2020 1:19 pm

astaib wrote: ↑Sat Jun 06, 2020 6:37 am Waouh impressive values! Makes me dream.
Unfortunately it is not possible to install PF on the DA40 anymore.

??? Stephen just ordered one.

I had an email from prowerflow that told me this 1 month ago.

All hours tach, below
My original installation: 2006, 450 hrs.
Insert replaced: 2010, 830 hrs.
State of current insert today: 1280 hrs.:
Not quite in focus, but that inner perforated tube is in good shape its whole length. Glass is long gone, of course. The fate of all glass packs. I have a new insert which I plan to install during annual next month.